Controllable coupling assembly and coupling member for use in the assembly

ABSTRACT

A controllable coupling assembly and a coupling member for use in the assembly are provided. The member includes a first coupling face oriented to face axially along a rotational axis and has a set of locking formations angularly-spaced about the axis. The member also includes a second coupling face having a reverse pocket which receives a reverse locking element. The pocket defines a first load-bearing surface adapted for abutting engagement with a load-bearing surface of the reverse locking element. The second coupling face is oriented to face radially with respect to the axis. Each of the set of locking formations defines a second load-bearing surface adapted for abutting engagement with a load-bearing surface of a forward locking element.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. Nos. 14/675,850 and 14/675,853 both filed Apr. 1, 2015. Those applications are continuation-in-part of U.S. application Ser. No. 14/288,819 filed May 28, 2014, now U.S. Pat. No. 9,234,552, which claims benefit of U.S. provisional application Ser. No. 61/941,741 filed Feb. 19, 2014. This application is also related to U.S. application Ser. Nos. ______ and ______, filed on the same date as this application, and having attorney docket nos. MEII 0328 PUSP4 and MEII 0328 PUSP5.

TECHNICAL FIELD

This invention generally relates to controllable coupling assemblies and coupling members for use in such assemblies.

OVERVIEW

Coupling assemblies such as clutches are used in a wide variety of applications to selectively couple power from a first rotatable driving member, such as a driving disk or plate, to a second, independently rotatable driven member, such as a driven disk or plate. In one known variety of clutches, commonly referred to as “one-way” or “overrunning” clutches, the clutch engages to mechanically couple the driving member to the driven member only when the driving member rotates in a first direction relative to the driven member. Further, the clutch otherwise permits the driving member to freely rotate in the second direction relative to the driven member. Such “freewheeling” of the driving member in the second direction relative to the driven member is also known as the “overrunning” condition.

One type of one-way clutch includes coaxial driving and driven plates having generally planar clutch faces in closely spaced, juxtaposed relationship. A plurality of recesses or pockets is formed in the face of the driving plate at angularly spaced locations about the axis, and a strut or pawl is disposed in each of the pockets. Multiple recesses or notches are formed in the face of the driven plate and are engageable with one or more of the struts when the driving plate is rotating in a first direction. When the driving plate rotates in a second direction opposite the first direction, the struts disengage the notches, thereby allowing freewheeling motion of the driving plate with respect to the driven plate.

When the driving plate reverses direction from the second direction to the first direction, the driving plate typically rotates relative to the driven plate until the clutch engages. As the amount of relative rotation increases, the potential for an engagement noise also increases.

Controllable or selectable one-way clutches (i.e., OWCs) are a departure from traditional one-way clutch designs. Selectable OWCs add a second set of locking members in combination with a slide plate. The additional set of locking members plus the slide plate adds multiple functions to the OWC. Depending on the needs of the design, controllable OWCs are capable of producing a mechanical connection between rotating or stationary shafts in one or both directions. Also, depending on the design, OWCs are capable of overrunning in one or both directions. A controllable OWC contains an externally controlled selection or control mechanism. Movement of this selection mechanism can be between two or more positions which correspond to different operating modes.

U.S. Pat. No. 5,927,455 discloses a bi-directional overrunning pawl-type clutch, U.S. Pat. No. 6,244,965 discloses a planar overrunning coupling, and U.S. Pat. No. 6,290,044 discloses a selectable one-way clutch assembly for use in an automatic transmission. U.S. Pat. Nos. 7,258,214 and 7,344,010 disclose overrunning coupling assemblies, and U.S. Pat. No. 7,484,605 discloses an overrunning radial coupling assembly or clutch.

A properly designed controllable OWC can have near-zero parasitic losses in the “off” state. It can also be activated by electro-mechanics and does not have either the complexity or parasitic losses of a hydraulic pump and valves.

In a powershift transmission, tip-in clunk is one of most difficult challenges due to absence of a torque converter. When the driver tips-in, i.e., depresses the accelerator pedal following a coast condition, gear shift harshness and noise, called clunk, are heard and felt in the passenger compartment due to the mechanical linkage, without a fluid coupling, between the engine and powershift transmission input. Tip-in clunk is especially acute in a parking-lot maneuver, in which a vehicle coasting at low speed is then accelerated in order to maneuver into a parking space.

In order to achieve good shift quality and to eliminate tip-in clunk, a powershift transmission should employ a control strategy that is different from that of a conventional automatic transmission. The control system should address the unique operating characteristics of a powershift transmission and include remedial steps to avoid the objectionable harshness yet not interfere with driver expectations and performance requirements of the powershift transmission. There is a need to eliminate shift harshness and noise associated with tip-in clunk in a powershift transmission.

For purposes of this disclosure, the term “coupling” should be interpreted to include clutches or brakes wherein one of the plates is drivably connected to a torque delivery element of a transmission and the other plate is drivably connected to another torque delivery element or is anchored and held stationary with respect to a transmission housing. The terms “coupling”, “clutch” and “brake” may be used interchangeably.

A pocket plate may be provided with angularly disposed recesses or pockets about the axis of the one-way clutch. The pockets are formed in the planar surface of the pocket plate. Each pocket receives a torque transmitting strut, one end of which engages an anchor point in a pocket of the pocket plate. An opposite edge of the strut, which may hereafter be referred to as an active edge, is movable from a position within the pocket to a position in which the active edge extends outwardly from the planar surface of the pocket plate. The struts may be biased away from the pocket plate by individual springs.

A notch plate may be formed with a plurality of recesses or notches located approximately on the radius of the pockets of the pocket plate. The notches are formed in the planar surface of the notch plate.

Another example of an overrunning planar clutch is disclosed in U.S. Pat. No. 5,597,057.

Some U.S. patents related to the present invention include: U.S. Pat. Nos. 4,056,747; 5,052,534; 5,070,978; 5,449,057; 5,486,758; 5,678,668; 5,806,643; 5,871,071; 5,918,715; 5,964,331; 5,979,627; 6,065,576; 6,116,394; 6,125,980; 6,129,190; 6,186,299; 6,193,038; 6,386,349; 6,481,551; 6,505,721; 6,571,926; 6,814,201; 7,153,228; 7,275,628; 8,051,959; 8,196,724; and 8,286,772.

Yet still other related U.S. patents include: U.S. Pat. Nos. 4,200,002; 5,954,174; and 7,025,188.

U.S. Pat. No. 6,854,577 discloses a sound-dampened, one-way clutch including a plastic/steel pair of struts to dampen engagement clunk. The plastic strut is slightly longer than the steel strut. This pattern can be doubled to dual engaging. This approach has had some success. However, the dampening function stopped when the plastic parts became exposed to hot oil over a period of time.

Metal injection molding (MIM) is a metalworking process where finely-powdered metal is mixed with a measured amount of binder material to comprise a ‘feedstock’ capable of being handled by plastic processing equipment through a process known as injection mold forming. The molding process allows complex parts to be shaped in a single operation and in high volume. End products are commonly component items used in various industries and applications. The nature of MIM feedstock flow is defined by a science called rheology. Current equipment capability requires processing to stay limited to products that can be molded using typical volumes of 100 grams or less per “shot” into the mold. Rheology does allow this “shot” to be distributed into multiple cavities, thus becoming cost-effective for small, intricate, high-volume products which would otherwise be quite expensive to produce by alternate or classic methods. The variety of metals capable of implementation within MIM feedstock are referred to as powder metallurgy, and these contain the same alloying constituents found in industry standards for common and exotic metal applications. Subsequent conditioning operations are performed on the molded shape, where the binder material is removed and the metal particles are coalesced into the desired state for the metal alloy.

Other U.S. patent documents related to at least one aspect of the present invention includes U.S. Pat. Nos. 9,255,614; 9,234,552; 9,127,724; 9,109,636; 8,888,637; 8,813,929; 8,491,440; 8,491,439; 8,286,772; 8,272,488; 8,187,141; 8,079,453; 8,007,396; 7,942,781; 7,690,492; 7,661,518; 7,455,157; 7,455,156; 7,451,862; 7,448,481; 7,383,930; 7,223,198; 7,100,756; and 6,290,044; and U.S. published application Nos. 2015/0061798; 2015/0000442; 2014/0305761; 2013/0277164; 2013/0062151; 2012/0152683; 2012/0149518; 2012/0152687; 2012/0145505; 2011/0233026; 2010/0105515; 2010/0230226; 2009/0233755; 2009/0062058; 2009/0211863; 2008/0110715; 2008/0188338; 2008/0185253; 2006/0124425; 2006/0249345; 2006/0185957; 2006/0021838, 2004/0216975; and 2005/0279602.

Some other U.S. patent documents related to at least one aspect of the present invention includes U.S. Pat. Nos. 8,720,659; 8,418,825; 5,996,758; 4,050,560; 8,061,496; 8,196,724; and U.S. published application Nos. 2014/0190785; 2014/0102844; 2014/0284167; 2012/0021862; 2012/0228076; 2004/0159517; and 2010/0127693.

As used herein, the term “sensor” is used to describe a circuit or assembly that includes a sensing element and other components. In particular, as used herein, the term “magnetic field sensor” is used to describe a circuit or assembly that includes a magnetic field sensing element and electronics coupled to the magnetic field sensing element.

As used herein, the term “magnetic field sensing element” is used to describe a variety of electronic elements that can sense a magnetic field. The magnetic field sensing elements can be, but are not limited to, Hall effect elements, magnetoresistance elements, or magnetotransistors. As is known, there are different types of Hall effect elements, for example, a planar Hall element, a vertical Hall element, and a circular vertical Hall (CVH) element. As is also known, there are different types of magnetoresistance elements, for example, a giant magnetoresistance (GMC) element, an anisotropic magnetoresistance element (AMR), a tunneling magnetoresistance (TMR) element, an Indium antimonide (InSb) sensor, and a magnetic tunnel junction (MTJ).

As is known, some of the above-described magnetic field sensing elements tend to have an axis of maximum sensitivity parallel to a substrate that supports the magnetic field sensing element, and others of the above-described magnetic field sensing elements tend to have an axis of maximum sensitivity perpendicular to a substrate that supports the magnetic field sensing element. In particular, planar Hall elements tend to have axes of sensitivity perpendicular to a substrate, while magnetoresistance elements and vertical Hall elements (including circular vertical Hall (CVH) sensing element) tend to have axes of sensitivity parallel to a substrate.

Magnetic field sensors are used in a variety of applications, including, but not limited to, an angle sensor that senses an angle of a direction of a magnetic field, a current sensor that senses a magnetic field generated by a current carried by a current-carrying conductor, a magnetic switch that senses the proximity of a ferromagnetic object, a rotation detector that senses passing ferromagnetic articles, for example, magnetic domains of a ring magnet, and a magnetic field sensor that senses a magnetic field density of a magnetic field.

SUMMARY

An object of at least one embodiment of the present invention is to provide a low cost controllable coupling assembly and a coupling member for use in the assembly.

In carrying out the above object and other objects of at least one embodiment of the present invention, a coupling member for use in a controllable coupling assembly is provided. The member includes a first coupling face oriented to face axially along a rotational axis and having a set of locking formations. Each of the set of locking formations defining a first load-bearing surface adapted for abutting engagement with a load-bearing surface of a first locking element. The member also includes a second coupling face oriented to face radially with respect to the axis. The second coupling face has a reverse pocket receiving a reverse locking element and defines a second load-bearing surface adapted for abutting engagement with a load-bearing surface of the reverse locking element.

The set of locking formations may be spaced-apart forward cams.

The set of locking formations may be forward locking formations.

The reverse locking element may be a radial pawl.

The coupling member may be an outer coupling member.

The assembly may further include a biasing member to bias the reverse locking element. The biasing member may bias the reverse locking element towards an uncoupling position.

Further in carrying out the above object and other objects of at least one embodiment of the present invention, a controllable coupling assembly having multiple operating modes is provided. The assembly includes first and second coupling members supported for rotation relative to one another about a common rotational axis in a first operating mode. The first coupling member includes a first coupling face oriented to face axially along the axis and having a set of locking formations. Each of the set of locking formations defines a first load-bearing surface adapted for abutting engagement with a load-bearing surface of a first locking element in a second operating mode. The first coupling member also includes a second coupling face oriented to face radially with respect to the axis. The second coupling face has a reverse pocket receiving a reverse locking element and defining a second load-bearing surface adapted for abutting engagement with a load-bearing surface of the reverse locking element in a third operating mode.

The second coupling member may be a plate and has a set of forward pockets angularly spaced about the axis and a set of spaced-apart reverse cams.

The reverse cams may be greater in number than the forward pockets.

The spaced-apart reverse cams may be spaced-apart locking teeth.

The plate has a width wherein each reverse cam may extend the entire width of the plate.

The second coupling member may be a splined ring having an outer circumferential surface formed with a set of locking formations.

The set of forward pockets may receive forward locking elements and the set of locking formations may be forward locking formations.

Still further in carrying out the above object and other objects of at least one embodiment of the present invention, a controllable coupling assembly for use in an electronic vehicular transmission is provided. The assembly includes first and second coupling members supported for relative rotation about a rotational axis. The first coupling member has a first coupling face oriented to face radially with respect to the axis. The second coupling member having a second coupling face oriented to face radially with respect to the axis and having a set of locking formations. Each of the locking formations defines a load-bearing second surface. The first coupling face is in close-spaced opposition to the second coupling face and has a reverse pocket defining a load-bearing first surface. A reverse locking element is received within the reverse pocket in an uncoupling position and is movable outwardly from the reverse pocket to a coupling position to couple the first and second coupling members together. The coupling position is characterized by abutting engagement of the reverse locking element with the load-bearing first and second surfaces. The assembly also includes an electromechanical component supported by the first coupling member. The component includes a housing part having a closed axial end, an electromagnetic source including at least one excitation coil at least partially surrounded by the housing part and a reciprocating member arranged concentrically relative to the at least one excitation coil. The reciprocating member is axially movable to move the reverse locking element to either the coupling position or the uncoupling position when the at least one excitation coil is supplied with current.

The reverse locking element may include at least one projecting leg portion. Each leg portion has an aperture. The assembly may further include a pivot pin received within each aperture to allow rotational movement of the locking element in response to reciprocating movement of the reciprocating member.

A leading end of the reciprocating member may be connected to the reverse locking element via the pivot pin.

The reverse locking element may be spring-loaded.

The housing part may have at least one attachment flange to attach the component to the first coupling member.

The locking formations may comprise radially extending, angularly-spaced teeth.

The component may comprise a solenoid.

The second coupling member has a width wherein each locking formation may extend the entire width of the second coupling member.

The assembly may further comprise a biasing member to bias the reciprocating member to an extended position.

The reciprocating member and the reverse locking element may be connected together.

While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a controllable coupling assembly and an electromechanical component constructed in accordance with at least one embodiment of the parent application to this application;

FIG. 2 is an exploded, perspective view of the assembly and component of FIG. 1;

FIG. 3 is a view of the assembly and component similar to the view of FIG. 2 but from a different angle;

FIG. 4 is an enlarged side view, partially broken away, of the assembly and component of FIG. 1 together with a second electromechanical component in phantom with locking elements of the components partially extended towards locking formations of a coupling member of the assembly;

FIG. 5 is a partial block diagram and side view, opposite the side view of FIG. 4, but with one of the components in cross section and inserted in a case (also in cross section) of an electronic vehicle transmission constructed in accordance with at least one embodiment of the parent application to this application;

FIG. 6 is a perspective, schematic bottom view of the electromechanical component of the prior Figures;

FIG. 7 is an exploded, perspective view of the electromechanical component;

FIG. 8 is a schematic perspective front view, partially broken away, of a controllable coupling assembly and an electromechanical component constructed in accordance with at least one embodiment of the present invention;

FIG. 9 is a view, similar to the view of FIG. 8, but showing the rear of the assembly and the component;

FIG. 10 is a side schematic view, partially broken away, of the component attached to a raised portion of an outer coupling member of the assembly via a bracket;

FIG. 11 is a view, similar to the view of FIG. 9, but showing the top of the assembly, the component and the bracket;

FIG. 12 is a view, similar to the FIG. 11, but without the bracket;

FIG. 13 is a schematic perspective top view of the bracket of FIG. 11;

FIG. 14 is a schematic perspective bottom view of the bracket of FIG. 13;

FIG. 15 is a schematic perspective view, partially broken away, of the rear of the outer coupling member with a supported component;

FIG. 16 is a top, schematic perspective view, partially broken away, of the coupling member of FIG. 15 without the component;

FIG. 17 is a side elevational view, partially broken away, of the coupling member of FIGS. 15 and 16;

FIG. 18 is a side, schematic perspective view, partially broken away, of the coupling member of FIGS. 15-17;

FIG. 19 is a schematic perspective top view of another embodiment of the electromechanical component with a printed current board with electrical components supported on a top surface of the component;

FIG. 20 is a side view, partially broken away and in cross section, of the component attached to the raised portion of the outer coupling member and with a radial pawl shown in its uncoupling or retracted position;

FIG. 21 is an enlarged side view, partially broken away and in cross section and similar to the view of FIG. 20, but further including a vented, spring-loaded plunger on the heel of a pawl which is in its extended, coupling position;

FIG. 22 is a schematic perspective bottom view, partially broken away and in cross section and similar to the view of FIG. 21, but also showing a speed sensor;

FIG. 23 is a side view, partially broken away and in cross section and similar to the views of FIGS. 21 and 22, with the pawl in its retracted position and further illustrating the inner coupling member;

FIG. 24 is an enlarged side view, partially broken away and in cross section, showing a spring-loaded radial pawl pushed by a plunger or reciprocating member of the electromechanical component into its coupling position in which the pawl abuttingly engages a tooth on the inner coupling member;

FIG. 25 is a view, similar to the view of FIG. 24, but with the plunger in its retracted position and the pawl in its “off” or uncoupling position; and

FIG. 26 is a view similar to the views of FIGS. 24 and 25 but with the pawl attached or connected to a free or distal end of the reciprocating member or plunger via a clevis-type connection (not dissimilar to the connection of FIG. 7); the coupling position of the pawl is shown by phantom lines.

DETAILED DESCRIPTION

As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

Referring now to the drawing figures, there is illustrated one embodiment of an electronic vehicular transmission, generally indicated at 10 in FIG. 5. The transmission 10 includes a transmission case 40 having a bore 41 which extends completely through the case 40. As is well known in the art, the transmission case 40 has associated therewith an environment which is hostile to electrical components during use of the transmission 10 primarily because of: (1) hot oil contained therein, (2) contaminants in the oil which cause shorting of any electrical circuits therein and (3) vibration.

The transmission 10 also includes an electromechanical component, generally indicated at 14, which is capable of operating in the hostile environment of the case 40. The component 14 may be referred to herein below as an SSI (i.e. selectable solenoid insert). The component 14 is inserted through the bore 41 and held therein by threaded fasteners (not shown) which extend through holes 46 formed through an annular flange 44 of a housing, generally indicated at 48, of the component 14. The fasteners extend into threshold holes 42 formed in the case 40 about the bore 41 to secure the component 14 to the case 40.

Referring now to FIGS. 1-3, the transmission 10 also includes a controllable coupling assembly, generally included at 12, which, in turn, includes first and second coupling members, 18 and 22, respectively, mounted for rotation relative to one another about a rotational axis 16. The first coupling member 18 has a first coupling face 19 oriented to face axially in a first direction with respect to the axis 16 and the second coupling member 22 has a second coupling face 23 oriented to face axially in a second direction opposite the first direction with respect to the axis 16. The second coupling member 22 also has a third coupling face 25 oriented to face radially with respect to the axis 16 and having a set of locking formations or teeth 30 formed therein. The teeth 30 are preferably ferromagnetic or magnetic teeth 30.

The coupling assembly 12 also includes a set of forward locking elements or struts 20 which are received within angularly spaced pockets 26 formed in the face 23 of the coupling member 22. The coupling member 22 has a set of splines 28 formed on its inner diameter for drivingly engaging a drive or driven member (not shown) for rotation about the axis 16.

The assembly 12 also includes a locking ring or plate, generally indicated at 24, for insertion into an annular groove 36 of an axially extending wall 37 of the coupling member 18 to hold the coupling members 18 and 22 together. The locking plate 24 has a circumferential cutout 34 which coincides or is aligned with a circumferential cutout 32 provided in the wall 37 of the member 18 when the plate 24 is inserted into the groove 36. This feature allows a locking element or strut 52 of the component 14 to engage the teeth 30 of the member 22 as shown in FIGS. 4 and 5.

The housing part or housing 48 has an outer coupling face 49 (FIG. 5) in close-spaced opposition to the coupling face 25 of the member 22 when the members 18 and 22 are joined and assembled together by the locking ring 24 and after insertion of the component 14 into the bore 41 of the case 40.

The outer coupling face 49 of the housing part 48 has a single, T-shaped recess or pocket 51. The recess 51 defines a load-bearing first surface shoulder 53. The coupling face 25 of the member 22 has a plurality of reverse notches or teeth 30. Each tooth of the teeth 30 defines a load-bearing second surface or shoulder 31.

The locking strut or element 52 is capable of extending between the coupling faces 25 and 49 of the member 22 and the part 48, respectively, between coupling and uncoupling positions when the assembly 12 and case 40 are assembled together as is shown in FIGS. 4 and 5.

The element 52 may comprise a ferromagnetic locking element or strut movable between first and second positions. The first position (i.e. coupling position) is characterized by abutting engagement of the locking element 52 with the load-bearing surface or shoulder 31 of one of the teeth 30 and the shoulder 53 of the pocket 51 formed in an end wall of the housing part 48. The second position (i.e. non-coupling position) is characterized by non-abutting engagement of the locking element 52 with a load-bearing shoulder 31 of at least one of the teeth 30 and the end wall of the housing part 48.

The electromechanical component or apparatus (i.e. SSI) 14 includes the housing part 48 which has a closed axial end including the end wall. The end wall has the outer coupling face 49 with the single pocket 51 which defines the load-bearing shoulder 53 which is in communication with an inner face of the end wall. The housing part 48 may be a metal (such as aluminum) injection molded (MIM) part.

The apparatus 14 also includes an electromagnetic source, including at least one excitation coil 62 which is at least partially surrounded by a skirt of the housing part 48.

Electrical insulated wiring 64 supplies electrical power to the coil 62 from a power source located outside the hot oil environment. The wiring 64 extends from the coil 62, through a hole 65 (FIG. 5) formed through an end seal 82, through a cavity 86 formed through an overmold 84 and to a solenoid controller.

The strut 52 is retained within the pocket 51 by a clevis-shaped retainer 50. The strut 52 is movable outwardly from the pocket 51 to its extended, coupling position characterized by abutting engagement of the strut 52 with a load-bearing surface or shoulder 31 of one of the teeth 30.

The apparatus 14 also includes a reciprocating plunger, generally indicated at 70, arranged concentrically relative to the at least one excitation coil 62 and is axially movable when the at least one excitation coil 62 is supplied with current via the wires 64. The coil 62 is wound or located about an actuator core or armature 76 and is potted between plates 60 and 78. The armature 76 is also axially movable upon coil excitation. The plate 60 abuts against the inner face of the housing end wall. The plunger 70 extends through a hole 61 (FIG. 7) formed through the plate 60 and is connected at its leading end 72 to the element 52 to move the element 52 between its coupling and uncoupling positions. The plunger 70 also extends through an aperture 75 formed through the armature 76. The opposite end of the plunger 70 has a locking nut or cap 80 positioned thereon which limits movement of the plunger 70 in the aperture 75 towards the teeth 30 by abutting against the lower surface of an annular spacer 68 which abuts against the lower surface of the armature 76.

The element 52 is pivotally connected to the apertured leading end 72 of the plunger 70 wherein the plunger 70 pivotally moves the element 52 within the pocket 51 in response to reciprocating movement of the plunger 70 which, in turn, moves axially in response to reciprocating movement of the armature 76.

The apparatus 14 also preferably includes a return spring 66, which extends between the plate 60 and a shoulder in the outer surface of the actuator core or armature 76, to return the plunger 70 and the armature 76 to their home position when the coil 62 is de-energized, thereby returning the element 52 to its uncoupling position. The apparatus 14 also includes a spring 74 which urges the plunger 70 to move the element 52 towards its coupling position. In other words, the biasing member or spring 66, urges the plunger 70 via the armature 76 to a return position which corresponds to its uncoupling position of the element 52 while the biasing member or spring 66 urges the plunger 70 and its connected element 52 to its coupled position.

The housing part 48 and/or the plate 78 may have holes (not shown) to allow oil to circulate within the housing part 48. Preferably, the at least one coil 62, the housing part 48, the armature 76 and the plunger 70 comprise a low profile solenoid. The locking element 52 may be a metal (such as aluminum) injection molded (i.e. MIM) strut.

The element 52 includes at least one and, preferably, two projecting leg portions 55 which provide an attachment location for the leading end 72 of the plunger 70. Each leg portion 55 has an aperture 57. The apparatus 14 further comprises a pivot pin 54 received within each aperture 57 and the aperture formed in the leading end 72 to allow rotational movement of the element 52 in response to reciprocating movement of the plunger 70 wherein the leading end 72 of the plunger 70 is connected to the element 52 via the pivot pin 54.

Preferably, each aperture 55 is an oblong aperture which receives the pivot pin 54 to allow both rotation and translational movement of the element 52 in response to reciprocating movement of the plunger 70. Each locking strut 52 may comprise any suitable rigid material such as ferrous metal, (i.e. steel).

The component 14 also includes a magnetic field speed sensor or device 56 which may comprise a differential Hall-effect device which senses speed of the teeth 30 as they rotate past the sensor 56. The teeth 30 may carry or support a rare-earth, automotive grade, magnet or pellet (not shown) which may be embedded in a hole formed in the outer surface of the teeth. In that case, the teeth 30 may be non-ferrous teeth such as aluminum teeth. Alternatively, and preferably, the teeth 30 are ferromagnetic teeth.

The device 56 is typically back-biased, has two wires 58 (FIG. 7) and provides a current output based on speed of rotation of the teeth 30 past the sensor 56. The device 56 accurately detects the speed with a single output (i.e., current output). The device 56 is preferably mounted adjacent to the pocket 51 and the wires 58 extend through the aperture 61 formed in the plate 60. The wires 58 and the wires 64 of the coil 62 are coupled to the solenoid controller which, in turn, is coupled to a main controller to supply drive signals to the coil 62 in response to control signals from the main controller. The device 56 may be held in place by fasteners or by an adhesive so that a side surface of the device 56 is in close proximity to a side surface of the strut 52 in the uncoupling position of the strut 52.

The sensor 56 is typically back-biased when the teeth 30 are ferromagnetic and typically includes a Hall sensor or sensing element mounted on a circuit board on which other electronics or components are mounted, as is well-known in the art. The sensor 56 is preferably back-biased in that it includes a rare-earth magnet which creates a magnetic flux or field which varies as the teeth 30 move past the sensor 56. The sensor 56 may comprise a back-biased, differential Hall Effect device.

In other words, the device 56 is preferably a back-biased device wherein the device 56 includes a rare earth pellet or magnet whose magnetic field varies as the teeth 30 move therepast. The variable magnetic field is sensed by the magnetic sensing element of the device 56.

The output signal from the device 56 is a feedback signal which is received by the solenoid controller. By providing feedback, the resulting closed-loop control system provides for true speed operation.

As described above, the number of forward struts (i.e. 14) is greater than the number of reverse struts (i.e. one or two). Also, the number of reverse notches is greater than the number of forward notches. In this situation, there is a possibility of a coupling assembly such as the coupling assembly 12 to enter a “lock-lock” condition wherein the transitional backlash (i.e., distance the clutch can move between forward and reverse directions) is extremely low. This results in the locking elements not being allowed to drop out of their coupling positions upon command.

In order to avoid the above-described problem, the number of reverse struts and notches and the number of forward struts and notches are chosen so that the forward backlash is a non-zero integer multiple (i.e. “N”) of the reverse backlash and the forward pockets are uniformly angularly spaced about the axis 16. The following is a table of 36 entries wherein only entries 11, 14 and 15 do not satisfy the above criteria.

Reverse Reverse Reverse Forward Forward Forward Transitional Entry N Notches Struts Backlash Notches Strut Sets Backlash Backlash 1 2 79 1 4.556962 79 2 2.278481 1.139241 2 2 77 1 4.675325 77 2 2.337662 1.168831 3 3 80 1 4.5 80 3 1.5 0.75 4 3 79 1 4.556962 79 3 1.518987 0.759494 5 3 77 1 4.675325 77 3 1.558442 0.779221 6 3 76 1 4.736842 76 3 1.578947 0.789474 7 3 74 1 4.864865 74 3 1.621622 0.810811 8 3 73 1 4.931507 73 3 1.643836 0.821918 9 3 71 1 5.070423 71 3 1.690141 0.84507 10 3 70 1 5.142857 70 3 1.714286 0.857143 11 3 62 1 5.806452 62 3 1.935484 0.967742 12 3 61 1 5.901639 61 3 1.967213 0.983607 13 3 59 1 6.101695 59 3 2.033898 1.016949 14 3 58 1 6.206897 58 3 2.068966 1.034483 15 3 56 1 6.428571 56 3 2.142857 1.071429 16 3 55 1 6.545455 55 3 2.181818 1.090909 17 3 53 1 6.792453 53 3 2.264151 1.132075 18 3 52 1 6.923077 52 3 2.307692 1.153846 19 1 79 2 2.278481 79 2 2.278481 1.139241 20 1 77 2 2.337662 77 2 2.337662 1.168831 21 1 79 3 1.518987 79 3 1.518987 0.759494 22 1 80 3 1.5 80 3 1.5 0.75 23 1 79 3 1.518987 79 3 1.518987 0.759494 24 1 77 3 1.558442 77 3 1.558442 0.779221 25 1 76 3 1.578947 76 3 1.578947 0.789474 26 1 74 3 1.621622 74 3 1.621622 0.810811 27 1 73 3 1.643836 73 3 1.643836 0.821918 28 1 71 3 1.690141 71 3 1.690141 0.84507 29 1 70 3 1.714286 70 3 1.714286 0.857143 30 1 61 3 1.967213 61 3 1.967213 0.983607 31 1 59 3 2.033898 59 3 2.033898 1.016949 32 1 58 3 2.068966 58 3 2.068966 1.034483 33 1 56 3 2.142857 56 3 2.142857 1.071429 34 1 55 3 2.181818 55 3 2.181818 1.090909 35 1 53 3 2.264151 53 3 2.264151 1.132075 36 1 52 3 2.307692 52 3 2.307692 1.153846

General Advantages

Wiring is outside the transmission.

Eliminates the difficulty in routing lead wires from the clutch around rotating parts to the bulk head inside the box.

Does not impact the number of wires passing through the bulk head connector.

Coils are potted, leads are over molded, connector is external, completely segregated from the hot oil environment which prevents:

Long term embrittlement of connector and wire insulation from hot oil exposure;

Eliminates the possibility of contamination in oil shorting the circuit to power; and

Vibration failures are greatly reduced (potted and over molded).

High Power Density—every surface of the inner and outer race is used. The radial surfaces are for reverse and the planar surfaces are for 1st gear. They are independent and do not compete for the same real estate in the races. The concentric design competes for radial cross section and co-planar designs add a PM race. The largest possible strut/cam geometry can be used in a smaller package. This increases the power density of the clutch.

Using the SSI 14 as a common electro-mechanical component.

Tend to make it a high volume commodity thus reducing cost.

Streamlines design, validation, and manufacturing—one and done approach.

Better resource allocation. Engineering can focus on clutch design without the burden of designing a new electro-mechanical solution for each unique application.

Eliminate the slide plate and failure modes associated with the slide plate.

Traditional MD approach—no concentric, co-planar design. Tried and true approach.

Cost competitive—highest power density, 2 races, and an across the board approach for controls using the SSIs 14.

Reduction of partial engagements.

The SSI 14 strut 52 turns on faster than a hydraulic design using a slide plate.

The SSI 14 can be turned on closer to the sync point when doing a rolling forward reverse shift because it takes only 20 ms or less to fire on. No hydraulic delay or temperature effects.

Soft Turn Off Capable Reduces Impact Loads when Turning Off

No special driver is required. The SSI 14 can fire initially and can be PWMed down to hold on. The higher pulse is to overcome a return spring designed for a 20 g impact.

NVH Advantages—Maximizing cams is great approach to reducing backlash. Many more cams can be formed into the race in the radial direction as opposed to the planar direction. Using the SSI 14 in the radial direction takes advantage of this feature.

Usually there is one outer race where the forward and reverse flanks of a spline are the path to ground. This design splits the paths. There is no backlash in the reverse direction as the path passes through a press fit SSI 14 into the case 40. The SSI 14 only reacts reverse torque. The outer race for the passive clutch conversely only sees forward reaction torque. The result is a system where the clutch does not travel through an external lash. The drive side spline stays on the drive side and the reverse drive path is in a press fit SSI 14. This reduces tick/clunk in the splines. A rubber washer/spring clip can be added to the coast side of the spline to keep the spline engaged with the case at all times. It never experiences reverse torque.

Advantages Over Hydraulic

Temperature insensitive.

Faster reaction time with small tolerance (20 ms or less).

Much less energy to operate over life of application.

Easier to route wires outside of box compared to packaging worm trails.

Easy for diagnostic—software maintenance loop with a trickle voltage can measure resistance for temperature, continuity, or a short instantly setting a code.

Contamination Insensitive

Advantages of Two Springs

If the armature 76 was directly connected to the strut 52 with a single return spring, a constant high current would have to be applied to ensure the device turns ON. The lowest stroking force occurs initially at the highest gap when the armature 76 is in the OFF position. If the armature 76 was directly attached to the strut 52 and the strut 52 was in between notches or teeth 30, a high current would have to be held to ensure the device would always stroke to ON eventually. The cam plate 22 would have to rotate so the strut 52 could drop in. So a consistently high current would have to be maintained as long as the solenoid 14 was ON. This is a problem. The solenoid 14 could overheat using this approach. The solution is to use two springs 66 and 76, an actuator core or armature 76, and a second internal piston called the plunger 70 that attaches to the strut 52 via a clevis connection. In this arrangement, the armature 76 always strokes ON and travels the full 3 mm closing the gap independent of the position of the strut 52 relative to the cams or teeth 30. The forces keeping the armature 76 in the ON position increase by a magnitude when the gap is closed. The armature 76 pushes the second spring 74 that pushes the plunger 70 attached to the strut 52.

Once the armature 76 strokes the 3 mm, the current can be dropped to a holding current that is a fraction of the initial pulse current. The strut 52 is loaded by the second spring 74 in the apply direction. If the strut 52 is in between cams or teeth 30, there is a second spring force pushing the strut 52 into the ON position as soon as the cam plate 22 rotates. The armature 70 is now independent of strut position and can be PWMed.

If one used a single spring in a tooth butt condition, the armature 76 would only stroke 1.3 mm and stop with a force of about 2 lbs. In a two-spring system the armature 76 always strokes the full 3 mm in 20 ms allowing the current to drop to a holding current. The second spring 74 applies the force to exit tooth butt.

Advantages of Speed Sensor with the Component (i.e. SSI)

The prior art has a speed sensor that passes through the outside of the outer race of the clutch to sense the speed of the inner race. It was presumed that it is for the non-sync reverse shift when rolling in the forward direction.

At least one embodiment of the present invention provides the structure for a speed sensor chip set. It is possible to pot in a speed sensor chip set right into the SSI 14. This has the advantage of flexing the structure of the SSI 14 to not only lock the inner race to ground in reverse, but also to sense the inner race speed all in the same part. This would eliminate the stand alone speed sensor, case machining and clutch machining to accommodate the stand alone speed sensor. This is a significant cost save.

Referring now to FIGS. 8-26, there is illustrated an embodiment of the present invention wherein parts which are the same or similar to the parts of FIGS. 1-7 in either structure and/or function have the same reference number added to the number “100”.

Also, parts of a second or third embodiment have the same reference number but a single or double prime designation, respectively.

A coupling and control assembly, generally indicated at 112, includes a speed sensor 156 (FIGS. 22-26) for providing an electrical signal for electronic transmission control. The sensor 156 is generally of the same type as the sensor 56 of FIGS. 1-7.

The assembly 112 includes a controllable coupling assembly, having first and second coupling members 118 and 122, respectively, supported for rotation relative to one another about a rotational axis 116. The electrical signal from the speed sensor 156 is based on the relative rotary speed of the second coupling member 122.

The first coupling member 118 has a first coupling face 149 (FIGS. 17 and 18) oriented to face radially with respect to the axis 116 and has a locking element 152 (FIGS. 20-23, 152′ in FIGS. 24 and 25 and 152″ in FIG. 26) disposed within a pocket or recess 151 (or 151′ or 151″, respectively). The recess 151 defines a load bearing first surface shoulder 153 or 153′ or 153″. The sensor 156 is also disposed within the recess 151 (or 151′ or 151″). The first coupling member 118 also has a coupling face 119 oriented to face axially with respect to the axis 116. The coupling face 119 (FIG. 22) has a set of axially spaced, locking formations 129 formed therein (FIGS. 17 and 18).

The second coupling member 122 has a set of splines 128 formed on its inner diameter (FIGS. 8, 9 and 23), a second coupling face 125 oriented to face radially with respect to the axis 116 and a set of ferromagnetic or magnetic locking formations or teeth 130 on its outer diameter. Each tooth 130 defines a load-bearing surface shoulder 131. The second coupling member 122 also has an axially facing coupling face 123 with a set of angularly spaced forward pockets 126 (one of which is shown in FIG. 22) for receiving and retaining a set of angularly spaced forward pawls (not shown but similar to the pockets 26 and the struts 20 in FIG. 2).

The first and second members 118 and 122, respectively, are positioned relative to each other so that the locking element 152 (or the locking elements 152′ and 152″) and the sensor 156 are in close-spaced opposition to the locking formations 130.

The assembly 112 also includes a locking ring or plate 124 for insertion into an annular groove 136 formed in an axially extending wall 137 of the coupling member 118 to hold the coupling members 118 and 122 together.

The first coupling member 118 includes a cutout or hole 132 which extends into a raised portion 135 of the member 118. A slit 127 extends completely through the member 118 from the hole 132 to the face 149.

The assembly 112 also includes a locking ring or plate 124 for insertion into an annular groove 136 formed in an axially extending wall 137 of the coupling member 118 to hold the coupling members 118 and 122 together.

The first coupling member 118 includes a cutout or hole 132 which extends into a raised portion 135 of the member 118. A slit 127 extends completely through the member 118 or from the hole 132 to the face 149.

The assembly 112 also includes an electromechanical component, generally indicated at 114 and 114′ (FIG. 19), and includes a reciprocating member 170 (or 170′ in FIG. 19). The component 114 is supported in the hole 132 so that the reciprocating member 170 reciprocates in the slit 127 and moves the locking element 152 across a gap between the coupling faces 149 and 125 in response to the component 114 receiving an electrical control signal. The locking element 152 abuttingly engage one of the locking formations 130 in a coupling position of the locking element 152 (i.e. FIGS. 21 and 24) to prevent relative rotation in one direction about the axis 116. The component 114 has a housing 148 which is held in the hole 132 by a u-shaped bracket 129 having legs 133 and a resilient gripping portion 135 which grip beveled portions 138 of the raised portion 135.

The component 114′ is preferably generally of the type disclosed in published U.S. patent application No. 2015/0061798. As described therein, the component 114′ is an electromagnetic solenoid 114′ including a housing 148′ and having a bottom part 160′ with an aperture 161′ in which the member 170′ reciprocates at a first end and a magnetic coil 162′ supported within the housing 148′ An armature 176′ is supported for axial movement within the housing 148′ between first and second positions when the coil 162′ is energized with a predetermined electrical current. The distance between the first and second positions defines a stroke length wherein the armature 176′ exerts a substantially constant force along its stroke length during axial movement of the armature 176′ between the first and second positions. A pin or the reciprocating member 170′ is biased by a spring 174′ which extends between the member 170′ and the armature 176′ to move axially between first and second positions. The spring 174′ biases the member 170′ towards the second coupling member 122.

The sensor 156 senses magnetic flux to produce an electrical output signal indicative of a speed of the relative rotation of the second coupling member 122. A variable magnetic field is generated in response to rotation of the locking formations 130 past the sensor 156.

The sensor 156 preferably includes a magnetic field sensing element. The sensor 156 may be back-biased wherein the locking formations 130 are ferromagnetic. The sensor 156 has wires 158 which together with the wires (not shown) of the coil 162 extend through a cavity 186 of an overmold 184 and are coupled to a solenoid controller.

The locking formations 130 may comprise radially extending, angularly-spaced teeth 130.

The locking element 152 or 152′ or 152″ is preferably a radial pawl.

As best shown in FIG. 22, the second coupling member 122 has a width wherein each locking formation 130 extends the entire width of the second coupling member 122.

The first coupling member 118 preferably is an outer coupling member and the second coupling member 122 is preferably an inner coupling member.

The assembly 112 may further comprise a spring or biasing member 166 or 166′ to bias the locking member 152 or 152′ or 152″, respectively, towards an uncoupling position as shown in FIGS. 22, 23 and 25. The biasing member 166 biases a vented pin 167 to engage the heel of the locking member 152 and bias the member 152 towards its uncoupling position. The pin 167 is vented to permit lubricating oil to flow therethrough.

The biasing member 174′ biases the reciprocating member 170′ to its extended position as shown in FIGS. 21 and 24.

A reciprocating member 170″ and a locking element 152″ of a different embodiment may be connected together as shown in FIG. 26 via a clevis-type connection. The connection is defined by a pair of spaced leg portions 155″ integrally formed at a bottom surface of the element 152″ which provide an attachment location for a leading or distal end 172″ of the reciprocating member 170″. As in the embodiment of FIGS. 1-7, each leg portion 155″ has an aperture 157″. A pivot pin 154″ is received within each aperture 157″ and an aperture formed in the leading end 172″ to allow rotational movement of the element 152″ in response to reciprocating movement of the reciprocating member 170″.

While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention. 

What is claimed is:
 1. A coupling member for use in a controllable coupling assembly, the member comprising: a first coupling face oriented to face axially along a rotational axis and having a set of locking formations, each of the set of locking formations defining a first load-bearing surface adapted for abutting engagement with a load-bearing surface of a first locking element; and a second coupling face oriented to face radially with respect to the axis and having a reverse pocket receiving a reverse locking element and defining a second load-bearing surface adapted for abutting engagement with a load-bearing surface of the reverse locking element.
 2. The coupling member as claimed in claim 1, wherein the set of locking formations are spaced-apart forward cams.
 3. The coupling member as claimed in claim 1, wherein the set of locking formations are forward locking formations.
 4. The assembly as claimed in claim 1, wherein the reverse locking element is a radial pawl.
 5. The assembly as claimed in claim 1, wherein the coupling member is an outer coupling member.
 6. The assembly as claimed in claim 1, further comprising a biasing member to bias the reverse locking element.
 7. The assembly as claimed in claim 6, wherein the biasing member biases the reverse locking element towards an uncoupling position.
 8. A controllable coupling assembly having multiple operating modes, the assembly comprising: first and second coupling members supported for rotation relative to one another about a common rotational axis in a first operating mode, the first coupling member including: a first coupling face oriented to face axially along the axis and having a set of locking formations, each of the set of locking formations defining a first load-bearing surface adapted for abutting engagement with a load-bearing surface of a first locking element in a second operating mode; and a second coupling face oriented to face radially with respect to the axis and having a reverse pocket receiving a reverse locking element and defining a second load-bearing surface adapted for abutting engagement with a load-bearing surface of the reverse locking element in a third operating mode.
 9. The assembly as claimed in claim 8, wherein the second coupling member is a plate and has a set of forward pockets angularly spaced about the axis and a set of spaced-apart reverse cams.
 10. The assembly as claimed in claim 9, wherein the reverse cams are greater in number than the forward pockets.
 11. The assembly as claimed in claim 9, wherein the spaced-apart reverse cams are spaced-apart locking teeth.
 12. The assembly as claimed in claim 9, wherein the plate has a width and wherein each reverse cam extends the entire width of the plate.
 13. The assembly as claimed in claim 8, wherein the second coupling member is a splined ring having an outer circumferential surface formed with a set of locking formations.
 14. The assembly as claimed in claim 9, wherein the set of forward pockets receive forward locking elements and the set of locking formations are forward locking formations.
 15. A controllable coupling assembly for use in an electronic vehicular transmission, the assembly comprising: first and second coupling members supported for relative rotation about a rotational axis, the first coupling member having a first coupling face oriented to face radially with respect to the axis and the second coupling member having a second coupling face oriented to face radially with respect to the axis and having a set of locking formations, each of the locking formations defining a load-bearing second surface, the first coupling face being in close-spaced opposition to the second coupling face and having a reverse pocket defining a load-bearing first surface, a reverse locking element received within the reverse pocket in an uncoupling position and movable outwardly from the reverse pocket to a coupling position to couple the first and second coupling members together, the coupling position being characterized by abutting engagement of the reverse locking element with the load-bearing first and second surfaces; and an electromechanical component supported by the first coupling member and including: a housing part having a closed axial end; an electromagnetic source including at least one excitation coil at least partially surrounded by the housing part; and a reciprocating member arranged concentrically relative to the at least one excitation coil and being axially movable to move the reverse locking element to either the coupling position or the uncoupling position when the at least one excitation coil is supplied with current.
 16. The assembly as claimed in claim 15, wherein the reverse locking element includes at least one projecting leg portion, wherein each leg portion has an aperture and wherein the assembly further includes a pivot pin received within each aperture to allow rotational movement of the locking element in response to reciprocating movement of the reciprocating member.
 17. The assembly as claimed in claim 16, wherein a leading end of the reciprocating member is connected to the reverse locking element via the pivot pin.
 18. The assembly as claimed in claim 15, wherein the reverse locking element is spring-loaded.
 19. The assembly as claimed in claim 15, wherein the housing part has at least one attachment flange to attach the component to the first coupling member.
 20. The assembly as claimed in claim 15, wherein the locking formations comprise radially extending, angularly-spaced teeth.
 21. The assembly as claimed 15, wherein the component comprises a solenoid.
 22. The assembly as claimed in claim 15, wherein the second coupling member has a width and wherein each locking formation extends the entire width of the second coupling member.
 23. The assembly as claimed in claim 15, further comprising a biasing member to bias the reciprocating member to an extended position.
 24. The assembly as claimed in claim 15, wherein the reciprocating member and the reverse locking element are connected together. 